Hydrogen generator

ABSTRACT

The present disclosure relates to a hydrogen generator with electrode and insulator configurations for providing hydrogen for fuel and reduced energy purposes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e)(1) to U.S. Provisional Patent Application Ser. No. 61/148,706, filed Jan. 30, 2009, entitled “Hydrogen Generator”; and the entire teachings of which are incorporated herein by reference.

BACKGROUND

A large number of companies in all industrial countries pursue attempts to generate hydrogen. Hydrogen is considered by many to be the fuel of the future for its abundant occurrence in nature as water and the non-toxic combustion by-product generated (water).

Large scale commercialization of Proton Exchange Membrane (PEM) fuel cells, requires an easily available source of hydrogen. To meet this requirement (i.e. hydrogen on demand) several methods are currently employed such as, pressurized hydrogen gas or liquid in a tank or hydrogen stored chemically as a hydride or generation of hydrogen in situ by catalytic reforming of natural gas and/or methanol or other hydrocarbons. Hydrogen gas stored in a tank or as hydride requires generation from other sources.

There are many problems with the prior art. For example, the size of the device needed to provide sufficient hydrogen fuel exceeds the space available to retrofit a device in need of hydrogen fuel. There is a general need to generate hydrogen for fuel applications in a more size and energy efficient manner.

SUMMARY

The present disclosure relates to fuel supplies and more particularly to hydrogen generators. Generally, embodiments according to the present disclosure relate to a device and method for generating hydrogen from an electrolyte. In one embodiment, the hydrogen generator contains a series of electrode plates, conductors and electrical insulators. The configuration of the electrode plates, conductors and insulators allows for the efficient generation of hydrogen when applied as an electrolytic cell in a hydrogen generation system.

In one embodiment, the hydrogen generating system comprises an electrolytic cell, or a plurality of electrolytic cells, energized by a direct current power source using direct current generator or alternator. The electrolytic cell is placed in contact with electrolyte, provided from an electrolyte reservoir, and the appropriate current is applied from the direct current power source. Upon electrolysis of the electrolyte, the evolved hydrogen gas is vacuum pumped from the electrolytic cell and drawn into a scrubber wherein the scrubber remove excess water and the resulting hydrogen gas is output for final use.

In one embodiment, the electrolytic cell or cells can be supplied by a continuous feed and/or intermittent of on demand electrolyte supply system. Increased capacities are possible due to high wattage loads attainable by the electrolytic cell without overheating. This is advantageous to produce the requisite amount of hydrogen gas fuel capable of operating automotive and other engines, for example, with a fuel mixture of hydrogen and only 20% to about 60% by volume of the gasoline fuel usually used in the engine. In some embodiments, the electrolytic cell or cells can be equipped with means to control energy load, water flow, gas flow, gas pressure, and presenting the hydrogen gas fuel into the combustion chambers of the automotive and other engines.

One possible embodiment is an electrode group comprising a first electrode assembly comprising a first electrode, a second electrode and a third electrode, a first conductor in communication between the second electrode and third electrode, a first insulator positioned between the second electrode and the third electrode, and the first electrode positioned spaced from and adjacent to the second electrode; a second electrode assembly comprising a fourth electrode, a fifth electrode and a sixth electrode, a second conductor in communication between the fourth electrode and the fifth electrode, a second insulator positioned between the fourth electrode and the fifth electrode, and the fifth electrode positioned spaced from and adjacent to the sixth electrode; and the third electrode positioned spaced from and adjacent to the fourth electrode.

Yet another possible embodiment is a method of generating hydrogen comprising: providing an electrode assembly comprising: a first electrode assembly comprising a first electrode, a second electrode and a third electrode, a first conductor in communication between the second electrode and third electrode, a first insulator positioned between the second electrode and the third electrode, and the first electrode positioned spaced from and adjacent to the second electrode; a second electrode assembly comprising a fourth electrode, a fifth electrode and a sixth electrode, a second conductor in communication between the fourth electrode and the fifth electrode, a second insulator positioned between the fourth electrode and the fifth electrode, and the fifth electrode positioned spaced from and adjacent to the sixth electrode; and the third electrode positioned spaced from and adjacent to the fourth electrode; and conducting current at least through the first electrode; then conducting current through a fluid electrolyte; then generating a gas from electrolysis of an electrolyte; then conducting current through the second electrode; then conducting current through the first conductor around the first insulator; then conducting current through the third electrode; then conducting current through the fluid electrolyte; then generating a gas from electrolysis of the fluid electrolyte; then conducting current through the fourth electrode; then conducting current through the second conductor around the second insulator; then conducting current through the fifth electrode; then conducting current through the fluid electrolyte; generating the gas from electrolysis of the electrolyte; and conducting current through the sixth electrode.

One embodiment is a vehicle comprising wheels, and an engine, the engine in fluid communication with a hydrogen generator containing an electrode group comprising: a first electrode assembly comprising a first electrode, a second electrode and a third electrode, a first conductor in communication between the second electrode and third electrode, a first insulator positioned between the second electrode and the third electrode, and the first electrode positioned spaced from and adjacent to the second electrode; a second electrode assembly comprising a fourth electrode, a fifth electrode and a sixth electrode, a second conductor in communication between the fourth electrode and the fifth electrode, a second insulator positioned between the fourth electrode and the fifth electrode, and the fifth electrode positioned spaced from and adjacent to the sixth electrode; and the third electrode positioned spaced from and adjacent to the fourth electrode.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross section view of one embodiment of an electrode assembly for a hydrogen generator.

FIG. 2 is a cross section view of an alternative embodiment of the electrode assembly illustrated in FIG. 1.

FIG. 3 is a cross section view of an alternative embodiment of the electrode assembly illustrated in FIG. 1.

FIG. 4 is a perspective view of an embodiment of arrangements of electrode assemblies illustrated in FIG. 3 for a hydrogen generator, with insulators omitted for the sake of clarity.

FIG. 5A is a top elevational view of a sheet of metal used to make electrodes in FIGS. 1-4.

FIG. 5B is a side view of an electrode illustrated in FIG. 5A after forming the electrode, for use in a hydrogen generator.

FIG. 5C is an end view section of an electrode illustrated in FIG. 5B for use in a hydrogen generator.

FIG. 6 is a cross section view of one embodiment of a hydrogen generator with electrode groups, a power source, electrolyte reservoir, vacuum pump, and scrubber.

FIG. 7A is a perspective view of a vehicle in which one embodiment of the hydrogen generator of FIG. 6 is installed.

FIG. 7B is a perspective view of a boat in which one embodiment of the hydrogen generator of FIG. 6 is installed.

FIG. 7C is a perspective view of a lawn mower in which one embodiment of the hydrogen generator of FIG. 6 is installed.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Various embodiments will be described in detail with references to drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments of the amended claims.

Turning now to FIG. 1, one embodiment of an electrode group 110 comprises a first power source connector 120 which is in electrical communication with first electrode 130 a, and a second power source connector 125 which is in electrical communication with sixth electrode 140 c. Adjacent to electrode 130 a is second electrode 140 a. First electrode 130 a and second electrode 140 a are spaced a distance “z” apart from each other. Generally “130” and “140” designate electrodes. Electrodes 130 and electrodes 140 can be made from any material that can effectively conduct electricity to perform electrolysis. Materials such as stainless steel, carbon composites, nanoparticulates, precious metals (e.g. Pt and Au) are known in the art. Additionally, the surface area of electrodes 130 and electrodes 140 can be increased by scuffing the surface of the electrode plates, or alternatively by “dimpling” the electrode plates. Dimpling the plates can be achieved using methods known in the art such as using high pressure presses on electrode plates. Other means of increasing the surface area of electrode plates include chemical etching and laser etching. The increase in surface area increases the efficiency of the plate in comparison with the amount of space which the cell, and ultimately the entire hydrogen generator, occupies.

In some embodiments electrodes designated 140 are substantially parallel to each other. In other embodiments electrode pairs 140 and 130 spaced “z” apart are substantially parallel to each other. In other possible embodiments, when current is applied, electrodes 140 can act together as an anode or electrodes 140 can act together as a cathode, depending upon the polarity of the power supply. Additionally, when electrodes 140 are cathodes, electrodes 130, in some embodiments, will be anodes. When electrodes 140 are anodes, electrodes 130, in some embodiments, will be cathodes. The determination of anodes and cathodes is dependent upon the polarity of the power supply and how the power supply is in electrical communication with the electrode group 110.

In some embodiments, first electrode 130 a, second electrode 140 a, third electrode 140 b, first insulator 150 a and first connector 160 a comprise an electrode assembly 111 a. In other embodiments fourth electrode 130 b, fifth electrode 130 c, sixth electrode 140 c, second connector 160 b and second insulator 150 b comprise an electrode assembly 111 b.

In some embodiments, second electrode 140 a and third electrode 140 b are in electrical communication through a connector 160 a; fourth electrode 130 b and fifth electrode 130 c are in electrical communication through a second connector 160 b. Generally, connectors 160 a and 160 b can be made from any material that effectively conducts electricity. Connectors, such as connectors 160 a and 160 b, are generally referred to herein as connectors 160 or conductors. In other embodiments, the connectors 160 can be (i) made from the same or different material or (ii) the same or different form factor that allows the electrode to be in electrical communication. In one embodiment, the connectors 160 can also be manufactured from the same material as electrodes 140 and electrodes 130. In one embodiment the electrode conductor can be made from different materials than the electrode plates. In yet other embodiments the electrode conductors can be made from a wire, a mesh or even a steel weave fabric.

Spacing “z” can be determined in accordance with some of the embodiments of the present disclosure such that electrode 130 and electrode 140 are not in direct electrical communication (i.e. shorted), yet spaced sufficiently to allow electrolysis of fluid between the electrode 140 and electrode 130. In other embodiments, space z can be as close as practical without shorting of the electrodes, while the space “z” is sufficiently wide where precipitate formed does not impair the operation of the system.

In some embodiments, the spaced distance “z” between the electrode 130 and electrode 140 is in the range of from about 0.2 mm to about 4 mm. In other embodiments, the spaced distance “z” between the electrode 130 and electrode 140 is in the range of from about 0.2 mm to about 0.5 mm. In some embodiments the spaced distance z can be about 0.25 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.75 mm, about 1 mm, about 2 mm or even about 3 mm.

Interposed between second electrode 140 a and third electrode 140 b is a first insulator 150 a. Generally “150” designates insulators. Insulator 150 a insulates the electrode pair {first electrode 130 a/second electrode 140 a} from {third electrode 140 b/fourth electrode 130 b} electrode pair. Insulator 150 a serves to minimize or prevent current flow through the space between the anode/cathode pairs. In some embodiments, electrical insulators 150 can be made of any suitable material such as ceramics, plastics, nonconductive polymers, PVC, ABS, ABF and polymer composites such as glass packed PVC. In one embodiment, polymers such as polyacrylic comprises insulator 150.

In accordance with other embodiments, interposed between fourth electrode 130 b and fifth electrode 130 c is a second insulator 150 b. Insulator 150 b insulates the electrode pair {third electrode 140 b/fourth electrode 130 b} from {fifth electrode 130 c/sixth electrode 140 c} electrode pair. Insulator 150 b serves to minimize or prevent current flow through the space between the electrode pairs.

In another possible embodiment insulator 150 has the same area or slightly larger area than electrode 130 or electrode 140 adjacent to insulator 150, thus insulating electrode pairs in the electrolyte fluid. In other embodiments, insulator 150 area can be reduced by about 10% in size compared with the electrode 130 or electrode 140 areas. In yet other embodiments the insulator 150 can be reduced in area by about 15%, about 20%, about 25%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80% or even about 90% in size compared with electrode 130 areas or electrode 140 areas.

FIG. 2 illustrates yet another embodiment of the present disclosure of an electrode group 110. Electrode group 110 comprises a first power supply connector 120 which is in electrical communication with first electrode 130 a, and second power supply connector 125 which is in electrical communication with tenth electrode 140 e. Adjacent to first electrode 130 a is second electrode 140 a, spaced a distance “z” from each other. The electrode 130 and electrode 140 can be made from any material that can effectively conduct current to perform the electrolysis. Materials such as stainless steel, carbon composites, nanoparticulate, precious metals (e.g. Pt and Au) are known in the art. Additionally, the surface area of the electrodes 130 and electrodes 140 can be increased by scuffing the surface of the electrode plates, or alternatively by “dimpling” the electrode plates. Dimpling the plates can be achieved using methods known in the art such as using high pressure presses on electrode plates. Other means of increasing the surface area of electrode plates include chemical etching and laser etching. The increase in surface area increases the efficiency of the plate in comparison with the amount of space which the cell, and ultimately the entire hydrogen generator system, occupies.

In some embodiments, electrode group 110 contains electrode assemblies 111 a, 111 b, 111 c and 111 d.

Second electrode 140 a and third electrode 140 b are in electrical communication through a first connector 160 a. Fourth electrode 130 b and fifth electrode 130 c are in electrical communication through a second connector 160 b. Sixth electrode 140 c and seventh electrode 140 d are in electrical communication through a third connector 160 c. Eighth electrode 130 d and ninth electrode 130 e are in electrical communication through a fourth connector 160 d. Connectors 160 can be (i) made from the same or different conductive material or (ii) the same or different form factor. In one embodiment, the electrode conductor can be made from the same materials as the electrode plates. In other embodiments the electrode conductors can be made from a wire, a mesh or even a steel weave fabric.

Spacing “z” is determined such that anode 130 and cathode 140 are not in direct electrical communication, yet spaced sufficiently to allow electrolysis of fluid between the cathode 140 and anode 130. In some embodiments spacing “z” can be as close as practical without shorting of the electrodes, while the space z is sufficiently wide where precipitate formed does not impair the operation of the system.

In other embodiments, the spaced distance z between the anode plate 130 and cathode plate 140 is in the range of from about 0.2 mm to about 4 mm. In some embodiments the spaced distance z can be about 0.25 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.75 mm, about 1 mm, about 2 mm or even about 3 mm.

Interposed between second electrode 140 a and third electrode 140 b is an insulator 150 a. Insulator 150 a electrically insulates the electrode pair {first electrode 130 a/second electrode 140 a} from {third electrode 140 b/fourth electrode 130 b} pairs, serving to minimize or prevent the conduction of electricity through the space between the anode/cathode electrode pairs. The electrical insulator may be made of any suitable material such as ceramics, plastics, nonconductive polymers, PVC, ABS, ABF and polymer composites such as glass packed PVC. In one embodiment, polymers such as polyacrylic have been used for material to make insulator 150.

Interposed between fourth electrode 130 b and fifth electrode 130 c is an insulator 150 b. Insulator 150 b electrically insulates the electrode pair {third electrode 140 b/fourth electrode 130 b} from {fifth electrode 130 c/sixth electrode 140 c} electrode pairs, serving to minimize or prevent the conduction of electricity through the space between the electrode pairs.

Interposed between sixth electrode 140 c and seventh electrode 140 d is an insulator 150 c. Insulator 150 c electrically insulates the electrode pair {fifth electrode 130 c/sixth electrode 140 c} from {seventh electrode 140 d/eighth electrode 130 d} electrode pairs, serving to minimize or prevent the conduction of electricity through the space between the electrode pairs.

Interposed between eighth electrode 130 d and ninth electrode 130 e is an insulator 150 d. Insulator 150 d electrically insulates the electrode pair {seventh electrode 140 d/eighth electrode 130 d} from {ninth electrode 130 e/tenth electrode 140 e} electrode pairs, serving to minimize or prevent the conduction of electricity through the space between the electrode pairs.

In another possible embodiment, insulator 150 has the same area or slightly larger area than electrode 130 or electrode 140, thus insulating electrode pairs in the electrolyte fluid. In other embodiments insulator 150 area can be reduced by about 10% in size compared with the electrode 130 or electrode 140 areas. In yet other embodiments the insulator 150 can be reduced in area by about 15%, about 20%, about 25%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80% or even about 90% in size compared with electrode 130 areas or electrode 140 areas.

FIG. 3 illustrates yet another embodiment of the present disclosure of an electrode group 310. Electrode group 310 comprises a first power supply connector 320 which is in electrical communication with first electrode 330 a, and second power supply connector 325 which is in electrical communication with tenth electrode 340 e. Adjacent to first electrode 330 a is second electrode 340 a, spaced a distance “z” from each other. The electrode 330 and electrode 340 can be made from any material that can effectively conduct current to perform the electrolysis. Materials such as stainless steel, carbon composites, nanoparticulate, precious metals (e.g. Pt and Au) are known in the art. Additionally, the surface area of the anode 330 and cathode 340 can be increased by scuffing the surface of the electrode plates, or alternatively by “dimpling” the electrode plates. Dimpling the plates can be achieved using methods known in the art such as using high pressure presses on electrode plates. Other means of increasing the surface area of electrode plates include chemical etching and laser etching. The increase in surface area increases the efficiency of the plate in comparison with the amount of space which the cell, and ultimately the entire hydrogen generator system, occupies.

In some embodiments, electrode group 310 contains electrode assemblies 311 a, 311 b, 311 c and 311 d.

Second electrode 340 a and third electrode 340 b are in electrical communication through a first connector 360 a. Fourth electrode 330 b and fifth electrode 330 c are in electrical communication through a second connector 360 b. Sixth electrode 340 c and seventh electrode 340 d are in electrical communication through a third connector 360 c. Eighth electrode 330 d and ninth electrode 330 e are in electrical communication through a fourth connector 360 d. Connectors 360 can be (i) made from the same or different conductive material or (ii) the same or different form factor. In one embodiment, the electrode conductor can be made from the same materials as the electrode plates. In other embodiments the electrode conductors can be made from a wire, a mesh or even a steel weave fabric.

Spacing “z” is determined such that anode 330 and cathode 340 are not in direct electrical communication, yet spaced sufficiently to allow electrolysis of fluid between the cathode 340 and anode 330. In some embodiments spacing “z” can be as close as practical without shorting of the electrodes, while the space z is sufficiently wide where precipitate formed does not impair the operation of the system.

In other embodiments, the spaced distance z between the anode plate 330 and cathode plate 340 is in the range of from about 0.2 mm to about 4 mm. In some embodiments the spaced distance z can be about 0.25 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.75 mm, about 1 mm, about 2 mm or even about 3 mm.

Interposed between second electrode 340 a and third electrode 340 b is an insulator 350 a. Insulator 350 a electrically insulates the electrode pair {first electrode 330 a/second electrode 340 a} from {third electrode 340 b/fourth electrode 330 b} pairs, serving to minimize or prevent the conduction of electricity through the space between the anode/cathode electrode pairs. The electrical insulator may be made of any suitable material such as ceramics, plastics, nonconductive polymers, PVC, ABS, ABF and polymer composites such as glass packed PVC. In one embodiment, polymers such as polyacrylic have been used for material to make insulator 150.

Interposed between fourth electrode 330 b and fifth electrode 330 c is an insulator 350 b. Insulator 350 b electrically insulates the electrode pair {third electrode 340 b/fourth electrode 330 b} from {fifth electrode 330 c/sixth electrode 340 c} electrode pairs, serving to minimize or prevent the conduction of electricity through the space between the electrode pairs.

Interposed between sixth electrode 340 c and seventh electrode 340 d is an insulator 350 c. Insulator 350 c electrically insulates the electrode pair {fifth electrode 330 c/sixth electrode 340 c} from {seventh electrode 340 d/eighth electrode 330 d} electrode pairs, serving to minimize or prevent the conduction of electricity through the space between the electrode pairs.

Interposed between eighth electrode 330 d and ninth electrode 330 e is an insulator 350 d. Insulator 350 d electrically insulates the electrode pair {seventh electrode 340 d/eighth electrode 330 d} from {ninth electrode 330 e/tenth electrode 340 e} electrode pairs, serving to minimize or prevent the conduction of electricity through the space between the electrode pairs.

In another possible embodiment, insulator 350 has the same area or slightly larger area than electrode 330 or electrode 340, thus insulating electrode pairs in the electrolyte fluid. In other embodiments insulator 350 area can be reduced by about 10% in size compared with the electrode 330 or electrode 340 areas. In yet other embodiments the insulator 150 can be reduced in area by about 15%, about 20%, about 25%, about 30%, about 40%, about 50%, about 60%, about 70%, about 80% or even about 90% in size compared with electrode 330 areas or electrode 340 areas.

FIG. 4 is a perspective view of one embodiment illustrated in FIG. 3. Insulators 350 have been omitted for clarity of viewing. A first electrode assembly 311 a is positioned in the x-z plane. Second electrode assembly 311 b is rotated 180 degrees along the y-axis from the first electrode assembly 311 a and placed adjacent to first electrode assembly 311 a. Third electrode assembly 311 c is rotated 180 degrees along the y-axis from the second electrode assembly 311 b and placed adjacent to second electrode assembly 311 b. Fourth electrode assembly 311 d is rotated 180 degrees along the y-axis from the third electrode assembly 311 c and placed adjacent to third electrode assembly 311 c. First electrode assembly 311 a is diagonally disposed with respect to second electrode assembly 311 b. Second electrode assembly 311 b is diagonally disposed with respect to third electrode assembly 311 c. Third electrode assembly 311 c is diagonally disposed with respect to fourth electrode 311 d.

In some embodiments described herein, the staggered configuration of electrode assemblies causes the current to flow from one corner of an electrode assembly diagonally toward the other corner of the electrode assembly.

FIGS. 5A, 5B and 5C illustrate various views of one embodiment of an electrode of the present disclosure. FIG. 5A illustrates a top elevational view of a metal sheet 440 before being bent for use as an electrode 130 or 140 in the electrode assembly of the present disclosure. In this embodiment the electrode connector 446 is integrated into a second electrode plate 444 and a first electrode plate 442. Metal sheet 440 can be produced by methods known in the art such as stamping and cutting. The dimensions of the first electrode plate 442 and the second electrode plate 444 can ultimately be determined by the size of the hydrogen generator and the current to be passed through the hydrogen generator.

In one embodiment, the length of the second electrode plate 444 “x” and the length of the first electrode plate 442 “x′” can independently vary in the range from about 1 inch to about 8 feet. The width of the upstream electrode plate y and the length of the downstream electrode plate y′ can independently vary in the range from about 1 inch to about 8 feet. In some embodiments x and x′ can independently vary from about 1.5 inches, about 2 inches, about 3 inches, about 4 inches, about 5 inches, about 6 inches, about 7 inches, about 8 inches, about 9 inches, about 10 inches, about 11 inches, about 12 inches, about 13 inches, about 14 inches, about 15 inches, about 16 inches, about 17 inches, about 18 inches, about 2 feet, about 3 feet, about 4 feet, about 6 feet, and even in some cases about 7 feet.

In other embodiments y and y′ can independently vary from about 1.5 inches, about 2 inches, about 3 inches, about 4 inches, about 5 inches, about 6 inches, about 7 inches, about 8 inches, about 9 inches, about 10 inches, about 11 inches, about 12 inches, about 13 inches, about 14 inches, about 15 inches, about 16 inches, about 17 inches, about 18 inches, about 2 feet, about 3 feet, about 4 feet, about 6 feet, and even in some cases about 7 feet.

Although the drawing represents that the second electrode plate 444 and the first electrode plate 442 are rectangular, the second electrode plate 444 and the first electrode plate 442 can independently assume other geometrical shapes which can correspond to the need of the container which encloses the hydrogen generator. For example, but not meant to be limiting, it is envisioned the second electrode plate 444 and the first electrode plate 442 can independently attain circular, elliptical and/or polyhedral shapes.

FIG. 5B illustrates a side view of a bent electrode plate 450 after electrode plate 440 of FIG. 5A has been bent along lines 1 and 1′ of FIG. 5A. The resulting bent electrode plate 450 can offer several advantages over other means of making the second electrode plate 444 and the first electrode plate 442. In having an integrated electrode connector there are no weak solder points or wires whereby dirt or corrosion can interfere with the conduction of electricity by the conductor. Furthermore, the integrated electrode connector also offers rigidity to maintain the critical spacing between other electrodes once assembled in the hydrogen generator.

FIG. 5C illustrates a cross-section view of one embodiment of the bent electrode plate 450.

The length “m” of electrode connector 446 of FIGS. 5A, 5B and 5C is illustrated as only partially bridging the second electrode plate 444 and first electrode plate 442. Other embodiments are envisioned wherein the length m of electrode connector 446 independently bridges as much as half, three quarters, or even the full length y of the second electrode plate 444 and full length y′ of first electrode plate 442. The length of electrode connector m can be optimized according to conductive capacity of the current applied to the cell, in order to maintain manageable heat levels.

FIG. 6 illustrates an embodiment of a hydrogen generator 613. Vessel 680 comprises two side walls 615 a, 615 b, bottom wall 614, top wall 616 and back wall 636. The vessel 680 serves to hold fluids, such as electrolyte 623 and gas evolved from the electrodes 130, 140.

The hydrogen generator 613 is further comprised of a series of electrodes 130, 140 and insulators 150 as illustrated in FIG. 2 of the present disclosure. The hydrogen generator 613 includes two cells or cell assemblies 670 a, 670 b, which each include an electrode group similar to that shown in FIG. 2.

A power supply 619 is attached to the electrode groups via terminals 624 and 626. Terminals 624 and 626 distribute current to each of the two cells 670 a, 670 b. Terminals 624 and 626 are made from conductive materials such as copper, brass, high carbon steel or stainless steel. Examples of alternator direct current power supplies include, but are not limited to EcoTech 14V 325 A alternator, available from Ecoair Corporation, Hamden, Conn.; 40SI High Output Alternator, available from Delco Remy, Pendleton, Ind.; and 4860JB/4900PA Series High Output Alternator available from Leece-Neville, Arcade, N.Y.

In some embodiments, the power supply 619 can supply voltages in the range of 13-14 v, producing watts/in² in the electrode plates in the range of about 0.1 watts/in² to about 7 watts/in²; and with a direct current in the range of about 30 amps to about 55 amps. In yet other embodiments, the power supply 619 can switch polarity of the current at predetermined intervals. Examples of such intervals which can be used include 2 minutes, 4 minutes, 30 minutes or even as long as several hours.

The cells 670 a, 670 b are in fluid communication via electrolyte inlet 631 with an electrolyte reservoir 622, which holds electrolyte fluid 623. Additionally, separator 617 separates cells 670 a and 670 b. Separator 617 can also be designed to allow electrolyte fluid to circulate between cells 670 a and 670 b, either with fenestrations (nor shown) or by not contacting bottom wall 614 or top wall 616. Electrolyte reservoir 622 supplies electrolyte fluid 623 to cells 670 a, 670 b as needed, to keep electrodes 140 and 130 and insulators 150 bathed in electrolyte fluid. This allows for electrolysis of the electrolyte fluid 623 to produce the desired end product gas (e.g. hydrogen, oxygen, methane, methyl nitrate and the likes). The electrolyte fluid 623 is typically an aqueous solution, with dissolved salts such as seasalts, KOH, NaOH, NaHCO₃ (sodium bicarbonate) and sulfuric acid. In some embodiments 1% aqueous KOH is used as electrolyte fluid. In other embodiments 10% aqueous KOH can be used as electrolyte fluid.

Hydrogen gas, for example, from electrolysis, is generated at the electrodes 130 and 140. The hydrogen gas then bubbles through the electrolyte 623 and enters headspace 632 a, 632 b above cell assemblies 670 a, 670 b. Headspace 632 a, 632 b above cell assemblies 670 a and 670 b are in fluid communication via scrubber inlets 633 a and 633 b. Scrubber 621 is in fluid communication with a vacuum pump 618 via vacuum pump inlet 634 which serves to pump gas through vacuum outlet 635 (such as hydrogen and oxygen) produced from the cell assemblies 670 a and 670 b. Scrubber 621 functions to purify and remove unwanted fluid (e.g. water) from the gas, producing the vacuum output stream 635. Vacuum output stream 635 can then be directed to the final use, such as fuel for an internal combustion engine or a fuel cell (for example, but not limited to hydrogen).

Electrodes 130, 140 set into back wall 636 and front wall (not shown) of vessel 680 in grooves that are slightly larger than the width of the electrode, (i.e., “loose” set electrode) impart unexpected advantage to the hydrogen generator. The hydrogen generator with “loose” plates has higher efficiency installed in a vehicle when the vehicle is running, or in motion to induce vibration or jarring of the hydrogen generator. The “loose” electrode plates in the oversized grooves are more easily jarred to release gaseous hydrogen from the surface of the electrode, thus freeing up more surface area for redox of electrolyte fluid.

FIG. 7A is a perspective view of a vehicle 1000 with a hydrogen generator 613, in fluid communication with an engine 1200 via vacuum pump outlet 635. In one embodiment vehicle 1000 can have at least 2 wheels. In other embodiments vehicle 1000 can have at least 4 wheels and in yet other embodiments vehicle 1000 can have at least 18 wheels. In other alternative embodiments the vehicle 1000 can have a diesel engine or a hybrid fuel engine. In some embodiments the vehicle 1000 can be an automobile and in yet other embodiments the vehicle 1000 can be a truck.

FIG. 7B is a perspective view of a watercraft 1001 with a hydrogen generator 613 connected to a marine engine 1300 via vacuum pump outlet 635. In one embodiment, the watercraft 1001 is a boat. In yet other embodiments the watercraft 1001 is a ship. In alternative embodiments the marine engine 1300 can be an outboard motor or an inboard motor. In yet other embodiments the marine engine 1300 can be a diesel engine, for example, such as that found in a commercial fishing boat, battleship or submarine.

FIG. 7C is a perspective view of a lawn mower 1002 with a hydrogen generator 613 in fluid communication with a lawn mower engine 1400 via vacuum pump outlet 635.

Whereas the components, such as outlets, power supply, electrodes, insulators and electrolyte reservoirs of the hydrogen generator are illustrated in specific locations, one of skill in the art would recognize that the various components could be plumbed and wired in different configurations while still achieving the same desired functionality of the hydrogen generator of the present disclosure.

It is to be understood that inventions according to the present disclosure can be incorporated in many different constructions so that the generality of the preceding description is not to be superseded by the particularity of the attached drawings. Various alterations, modifications and/or additions may be incorporated into the arrangement of parts without departing from the spirit and scope of the embodiments of the disclosed invention and examples.

EXAMPLES

The hydrogen generator system used for this example is illustrated in FIG. 6, with the exception that the hydrogen generator had 4 electrode cells (40 electrodes) instead of 2 electrode cells as represented in the illustration. The overall dimensions were 13 inches (length)×4.25 inches (width)×7 inches (height). The electrode plates were made of stainless steel (20 gauge; grade is 316/316L) and submersed in electrolyte (1% KOH; aqueous). The enclosing vessel and insulators were manufactured from polyacrylic. Each electrode plate measured 3.5 inch×3.5 inch and the separations (z) between the cathode plates and anode plates were 0.25 mm. Each of the four (4) cells contains ten (10) electrode plates, for a total of 40 electrode plates. The power source (an EcoTech 14V 325 A alternator, available from Ecoair Corporation, Hamden, Conn.) was computer controlled to average about 50 amps at about 13 volts. Upon operating the hydrogen generator system for about 120 minutes, the average output of the system was measured at 11 liters of gas per minute. Gas production was measured based on weight loss under vacuum. The gas was pulled through a moisture trap and moisture recovered was returned to the cell to assure accurate readings. The gas generated included hydrogen with lesser amounts of oxygen, methane and methyl nitrate.

The hydrogen generator system was controlled using a computer to monitor the duty cycle. The computer was programmed to limit the draw to 50 amps. Additionally, the computer switched polarity of the hydrogen generator cells every 4 minutes thus reversing the current flow. Reversing the current flow allows the plates to stay cleaner longer and increases the life expectancy of the plates thus allowing for greater output. The watts/in² of electrode plates was calculated to be about 0.32 Watts/in². 

1. An electrode group comprising: a first electrode assembly comprising a first electrode, a second electrode and a third electrode, a first conductor in communication between the second electrode and third electrode, a first insulator positioned between the second electrode and the third electrode, and the first electrode positioned spaced from and adjacent to the second electrode; a second electrode assembly comprising a fourth electrode, a fifth electrode and a sixth electrode, a second conductor in communication between the fourth electrode and the fifth electrode, a second insulator positioned between the fourth electrode and the fifth electrode, and the fifth electrode positioned spaced from and adjacent to the sixth electrode; and the third electrode positioned spaced from and adjacent to the fourth electrode.
 2. The electrode group of claim 1, wherein the first and second insulators are electrical insulators; and the first conductor is in electrical communication and second conductor is in electrical communication.
 3. The electrode group of claim 1, comprising a series of alternating electrode assemblies arranged so that an anode is adjacent to a cathode.
 4. The electrode group of claim 3, comprising an even number of electrode assemblies.
 5. The electrode group of claim 1, wherein the second electrode and third electrode are substantially parallel; and adjacent electrodes are substantially parallel.
 6. The electrode group of claim 1, wherein at least two electrode assemblies are disposed diagonally to each other.
 7. The electrode group of claim 1, wherein the third electrode is positioned spaced from and adjacent to the fourth electrode in the range of from about 0.2 mm to about 4 mm.
 8. The electrode group of claim 3, wherein the electrodes consist essentially of stainless steel, precious metal, and combinations thereof.
 9. The electrode group of claim 1, wherein the first and second insulators are at least about 90% of the area relative to an adjacent electrode area.
 10. The electrode group of claim 2, wherein the electrical insulators consist essentially of polymer, polymer composite, glass, ceramic, and combinations thereof.
 11. A hydrogen generator comprising a power supply, the power supply comprising at least a first terminal in electrical communication with an anode and second terminal in communication with a cathode.
 12. The hydrogen generator of claim 11, wherein the power supply is a high output alternator.
 13. The hydrogen generator of claim 11, wherein the power supply: (i) is controlled to switch polarity of the first and second terminals; (ii) supplies voltages in the range of 13-14 v; (iii) produces in the range of about 0.1 watts/in² to about 7 watts/in²; and (iv) produces direct current in the range of about 30 amps to about 55 amps.
 14. The hydrogen generator of claim 11, further comprising a series of electrode means for electrolyzing fluid.
 15. The hydrogen generator of claim 11, further comprising insulating means for insulating adjacent electrodes.
 16. A method of generating hydrogen comprising: providing an electrode assembly comprising: a first electrode assembly comprising a first electrode, a second electrode and a third electrode, a first conductor in communication between the second electrode and third electrode, a first insulator positioned between the second electrode and the third electrode, and the first electrode positioned spaced from and adjacent to the second electrode; a second electrode assembly comprising a fourth electrode, a fifth electrode and a sixth electrode, a second conductor in communication between the fourth electrode and the fifth electrode, a second insulator positioned between the fourth electrode and the fifth electrode, and the fifth electrode positioned spaced from and adjacent to the sixth electrode; and the third electrode positioned spaced from and adjacent to the fourth electrode; and conducting current at least through the first electrode; then conducting current through a fluid electrolyte; then generating a gas from electrolysis of the fluid electrolyte; then conducting current through the second electrode; then conducting current through the first conductor around the first insulator; then conducting current through the third electrode; then conducting current through the fluid electrolyte; then generating a gas from electrolysis of the fluid electrolyte; then conducting current through the fourth electrode; then conducting current through the second conductor around the second insulator; then conducting current through the fifth electrode; then conducting current through the fluid electrolyte; then generating a gas from electrolysis of the fluid electrolyte; and conducting current through the sixth electrode.
 17. A vehicle comprising an engine, the engine in fluid communication with a hydrogen generator containing an electrode group comprising: a first electrode assembly comprising a first electrode, a second electrode and a third electrode, a first conductor in communication between the second electrode and third electrode, a first insulator positioned between the second electrode and the third electrode, and the first electrode positioned spaced from and adjacent to the second electrode; a second electrode assembly comprising a fourth electrode, a fifth electrode and a sixth electrode, a second conductor in communication between the fourth electrode and the fifth electrode, a second insulator positioned between the fourth electrode and the fifth electrode, and the fifth electrode positioned spaced from and adjacent to the sixth electrode; and the third electrode positioned spaced from and adjacent to the fourth electrode.
 18. The vehicle of claim 17, comprising at least two (2) wheels.
 19. The vehicle of claim 18, comprising at least eighteen (18) wheels.
 20. The vehicle of claim 19, wherein the engine is a diesel fuel engine.
 21. The vehicle of claim 18, wherein the engine is a hybrid fuel engine.
 22. The vehicle of claim 17, wherein the vehicle is a ship having a diesel engine. 